This work presents a Set-Based Design inspired approach for generation, evaluation and reduction of a solution space of alternative product concepts. Also, the aspect of how to implement the process in an industrial environment was investigated. The hypothesis, confirmed by case studies, is that it can be done using existing methods like Enhanced functional modelling, brainwriting, the Gallery method, Axiomatic Design, causal diagrams and Pugh matrices. The method can be successfully introduced in a timeframe of a few working days and support development engineers in the concept design phase.

Manufacturing process selection presents numerous challenges to designers, including product complexity, consideration of production volumes and part tolerances. This paper introduces a design support tool based on the axiomatic design model to systematically transform requirements into functions and technological capabilities. The results from an evaluation of the implemented prototype tool in the field of medical device design demonstrates its usefulness in selecting the most suitable candidate manufacturing process for a given artifact, while taking into account multiple user requirements.

Topology optimization has been identified as a powerful tool to improve aircraft structures for many years. Yet, innovative layouts have not been successfully implemented in commercial aircraft for several reasons. One reason identified by our research group is the lack of design constraints during topology optimization, such as buckling stability, which yields complex solutions that are not easily manufacturable. Second, the complexity of the resulting layouts makes integration with other systems highly challenging. With respect to these challenges, we propose a new heuristic layout optimization process: complexity-driven layout exploration for aircraft structures (CD-LEAS). The new process addresses the challenges of complexity and nonlinear constraints, such as buckling, in aircraft structure layout optimization. The novelty of CD-LEAS comes from the integration of a relative complexity metric as a driver to navigate the design space efficiently. Two case studies of commonly used stiffened panels are carried out to showcase the performance of the process. The results show that using complexity to navigate an explicit design space allows our process to quickly output a family of simple, light, stiff and buckling-resistant layouts.

This paper introduces a method to improve the design procedure of axiomatic design theory (AD) with Extenics. A comprehensive review of the AD indicates that the powerful principle of AD has been widely studied and applied to many areas, however, inexperienced practitioners of the AD theory still find it difficult to follow or apply the principles in their design which inadvertently often leads to misunderstanding and skepticism. The lack of definitive descriptions for all the elements and specific approaches to guiding the mapping process restricts the development and application of AD theory. This paper improves the design procedure of AD with Extenics. The elements in AD domain are expressed by basic-elements of Extenics, and the formulations are generated. The mapping process based on AD and Extenics is developed. The improved design procedure provides designers with a theoretical foundation based on the logical and rational thought process, meanwhile the solution space can be expanded and innovative designs are inspired. Based on the proposed design procedure, a computer-aided system is developed, which makes the complex and fuzzy design activity clear and easy to follow by filling in the blanks in a step-by-step manner. An example of a novel corn harvester header design scheme is considered to illustrate the validity of the improved design procedure.

Flexibility and changeability are crucial when it comes to the design of embedded automotive architectures. However, flexibility and changeability are concepts rooted in the overall product and its objectives, while architectural design decisions may affect local subsystems as well as the overall system. Axiomatic design is applied to bridge this gap: The architecture is decomposed into its entities and changeability is described through the design's information content. Five domains of actions to foster changeability are identified and generic action schemes are derived.

In the traditional Axiomatic Design (AD) theory, the mapping from the functional domain to the physical domain is based on the designers’ own knowledge and experience, and there is no systematical approach including the design resources provided outside the designers themselves’ access. Thus, the raw materials for the design process are largely limited, which means they can hardly support the designers’ increasingly creative and innovative conceptions. To help AD theory better support the design process, this paper proposes a computer-aided approach for the mapping from the functional domain to the physical domain within a distributed design resource environment, which consists of numerous design resources offered on the Internet by the providers widely distributed in different locations, institutes, and disciplines. To prove the feasibility of this proposed approach, a software prototype is established, and a natural leisure hotel is designed as an implementation case.

Product development involves multiple phases. Design review (DR) is an essential activity formally conducted to ensure a smooth transition from one phase to another. Such a formal DR is usually a multicriteria decision problem, involving multiple disciplines. This paper proposes a systematic framework for DR using fuzzy set theory. This fuzzy approach to DR is considered particularly relevant for several reasons. First, information available at early design phases is often incomplete and imprecise. Second, the relationships between the product design parameters and the review criteria cannot usually be exactly expressed by mathematical functions due to the enormous complexity. Third, DR is frequently carried out using subjective expert judgments with some degree of uncertainty. The DR is defined as the reverse mapping between the design parameter domain and design requirement (review criterion) domain, as compared with Suh's theory of axiomatic design. Fuzzy sets are extensively introduced in the definitions of the domains and the mapping process to deal with imprecision, uncertainty, and incompleteness. A simple case study is used to demonstrate the resulting fuzzy set theory of axiomatic DR.